One of the most exciting developments in recent years has been the rise of the 3D printer. These printers allow individuals to create nearly any object they can think of, right in their own home – no additional tools or machinery required. Now, with the help of a 3D printer, you can make any part of a car or boat that you can think of, in a fraction of the time it would take to get the same item made by conventional means.
Stainless steel has long been known for its wear-resistance and high-strength, which made it the perfect material for use in automobiles and appliances that are regularly exposed to high temperatures and abrasive elements. This material also happens to be quite simple to print, as there are few, if any, machines or equipment required to complete a print. This versatility has made stainless steel the perfect choice for anyone who has a 3D printer.
Here's where it gets interesting. Not only can you make any part of a car or boat with a 3D printer, but you can actually make it look like it was made by a professional metal fabricator! It's not hard to see why. The end product is incredibly detailed, and sometimes even looks as good as the real thing. This raises an interesting question: could you ever replace a part on your vehicle (e.g., headlight, mirror, etc.) with something cheaper and more easily made? Could you ever replace a part on your home (e.g., sink, faucet, etc.) with something more efficient and cost-effective? Could you ever make your own jewelry, using recycled materials?
Let's take a closer look at the various techniques used by industrial metal fabricators, and how you can apply them to your own home. We'll begin with one of the most basic techniques and work our way up – galvanizing.
Galvanizing
One of the most widely used techniques for steel custom sheet metal fabrication is to first coat the surface with a thin layer of zinc. This process is called galvanizing. The reason behind this step is to provide a surface that is more resistant to corrosion and wear. The resulting material is known as galvanized steel. It is also available in a variety of colors, giving you the flexibility to choose the one that best matches your project.
The beauty of this process is that it takes less than an hour to complete. You won't need any additional equipment, other than a jig for cutting shapes out of metal. This makes it a great choice for anyone who has a 3D printer and some basic metalworking skills.
Phosphate Treatments
Another popular technique is to apply a phosphate treatment to the surface of the steel, prior to performing any other operation. This treatment is almost as good as galvanizing, but it has the added benefit of giving the metal a bright, shiny surface. Phosphate treatments are considered easier to apply than galvanizing, and they come with an added bonus of enhancing the strength of the metal.
The trouble with this treatment, however, is that it must be applied immediately after the steel is cut. If you wait until the end of the day to apply the treatment, the results will be less than optimal. Also, this treatment requires a bit more work, as you'll need to soak the steel in a chemical bath for 30 minutes, before applying the finish. It is a delicate process and must be performed with the utmost care. For this reason, it is not often used on large projects, where the outcome is not critical (e.g., a water faucet ornaments).
Electrochemical Etch
Another great way to modify the surface of steel is with an electrochemical etch. There are several prominent companies that provide this service, such as Anodizing Inc. and Surface Fabrication Company. The reason why electrochemical etching is so effective is that it allows for very precise control over the depth and shape of the resulting texture. It is best used on flat surfaces or very small curves. If you have a large area that needs to be textured, it would be better to use another method, such as the Brinell test or shot blasting – both of which we'll discuss next.
Brinell Test
The Brinell test is another method that is used to determine the hardness of steel. This test measures the indentation that a given amount of pressure makes on the surface of the material. The harder the steel, the deeper the indentation. This test is often performed on large samples of metal and is considered more accurate than using a Brink's hardness tester on a small piece of metal. This test is great for measuring the hardness of steel, but it is not used to "treat" the material – that is, to chemically change its composition or add additional layers to its surface.
Shot Blasting
Another method that is frequently used to modify the surface of steel is shot blasting. In this process, a very fine particle sand is blasted at high speed against the surface of the metal. The result is a very rough surface that is often used for cleaning or polishing. It is a very quick and easy process, and it can be used to great effect – as long as you have the right equipment. Be careful not to overexpose the steel to shot blasting or you may end up damaging it. This technique is great for getting very smooth, shiny surfaces on steel objects that will be subjected to very little wear. It is also a good choice for people who want to give their metals a unique look for decorative purposes.
Rolling
Another way of creating texture on steel is with a roller. These rollers, which are available from several different companies, such as Festool and Krause, come in a variety of shapes and sizes. They are used for creating waves, ripples, or other specific patterns on the surface of the steel. The beauty of this technique is that it is easy to apply and can be customized to fit any shape or curve. It is also a good choice for people who want to give their steel a distinctive look and feel.
Pearlizing
Still another way of adding texture to steel is with pearlizing. This is a technique that is frequently used in the jewelry industry, where it is known as hard enamel pearlizing. It is a process that combines enameling with steel fabrication. In this process, the metal is first cleaned and then etched, using a mixture of acids and water. Afterward, the surface is dried and a semi-transparent, natural pearl powder is hand-rubbed over the entire surface. This makes the steel look like it has been dipped in liquid nitrogen – very cool and unique! It is best used on ornamental pieces or small accessories, as it could be easily damaged by heavy wear or friction, such as on a faucet handle or bolt head.
Anodizing
Anodizing is another process that can be used to add a unique texture to steel. This process, which is sometimes called electrochemical oxidation, adds a semi-transparent coating to the material. It is a very popular technique for people who want to add a layer of protection against the elements. It is also a quick and easy process that can be customized to fit any shape or curve. This process is ideal for people who want to give their steel a unique look for decorative purposes.
Plating
Still another technique that can be used to alter the surface of steel is plating. In this process, a thin layer of metal is deposited on the surface of the steel. The beauty of this technique is that it can be done in any color or pattern that is desired. There are several different types of plating available, including bright nickel, antique silver, and semi-bright gold. This process is a great way to make your steel look like it comes from a luxury brand – very high quality yet affordable!
PVD Coatings
A specialized type of plating known as "physical vapor deposition" (PVD) can also enhance the strength of steel while creating a unique surface pattern. This is a great choice for people who want to add a layer of protection against the elements or those who want to make their steel look like it came from a luxury brand. It is also used for making water-resistant seals for electronic devices (e.g., water-proofing a smartphone or tablet). This coating is very similar to plate or anodizing, in that it is a very thin layer of metal that is applied to the surface of steel. However, one of the major differences is that the PVD coating can be applied with greater precision and in much greater thicknesses. This makes it a very good choice for people who want to add additional texture, pattern, or color to their steel.